Hollow metal door construction



Dec. 29, 1953 BOUGHTON HOLLOW METAL DOOR CONSTRUCTION Filed May 15, 1948 4 Sheets-Sheet l ATTORNEXS Dec. 29, 1953 E. BOUGHTON HOLLOW METAL DOOR CONSTRUCTION 4 Sheets-Sheet 2 Filed May 13, 1948 II/ rIl/IIII/II/l/ IN V EN TOR.

ATTORNEYS EARL BOUGH TON ATTORNEYS Patented Dec. 29, 1953 UNITED STATES PATENT OFFICE 2,664,181 HOLLOW METAL DOOR CONSTRUCTION Earl Boughton, Canton, Ohio Application May 13, 1948, Serial No. 26,768

12 Claims.

This invention relates to hollow sheet metal doors of the kind intended to be mounted on hinges for use in the doorways of buildings.

In the production of metal doors of this kind as heretofore carried out, the manufacturing operations have been slow and cumbersome and frequently have required the use of considerable hand labor and the use of special tools and equipment. The rate of production for such metal doors has accordingly been low in relation to the man-hours of labor consumed and in relation to the capital invested in tools, dies and other equipment. This has been particularly true in regard to providing reinforcements on. metal doors to adapt them for the mounting of hinges and locks thereon, because these reinforcements have heretofore usually required careful fitting and assembly operations which greatly increase the labor costs and frequently can be carried out only by the use of special tools and equipment.

As its principal object, this invention provides a novel method of manufacture and an improved construction for metal doors of the character indicated, by which the rate of production of such doors can be greatly accelerated and the cost of the manufacture decreased correspondingly. I

Another object is to'provide a novel method and improved construction for metal doors in which preformed component door parts are assembled in two groups so as to form two similar units or subassemblies on which the various cooperating connecting portions are exposed and readily accessible for performing welding operation thereon with conventional welding equipment, and which units are then assembled in complemental relation to form a hollow door structure and are welded together in such complemental relation by a welding tool inserted into the hollow door structure.

A further object is to provide a novel method and improved construction for metal doors in which preformed sheet metal panels are assembled in two groups to form two similar pan-like units on which the cooperating portions of adjacent panels are exposed and readily accessible for performing welding operations thereon, and which pan-like units are then assembled in complemental relation to form a hollow door structure and are welded together by a welding tool inserted into the hollow door structure.

Yet another object is to provide an improved metal door construction of the character mentioned in which the preformed panels of each unit include a hinge-stile panel and a lock-stile panel having cut-away portions to provide hingebutt and door-lock recesses, and in which reinforcements are welded in place in the hinge-stile and lock-stile panels adjacent the cut-away portions thereof prior to the assembly of said units in said complemental relation to form the hollow door structure.

Still another object is to provide an improved door construction of this character in which the reinforcements and the portions of the hingestile and lock-stile panels with which they cooperate are so formed that the reinforcements will be self-locating in the panels and can be quickly and easily assembled therein with a minimum labor requirement without need for any fitting operations and when thus assembled will be accurately positioned and readily accessible for carrying out welding operations thereon with facility and by the use of conventional welding equipment.

As another of its objects, this invention provides an improved metal door construction of the character mentioned in which the reinforcements of the respective units form complemental parts of a connecting means by which the units are connected together to form the hollow door structure.

Other objects and advantages of this invention will be apparent in the following detailed description and in the accompanying sheets of drawings in which:

Fig. 1 is a side elevation showing a hollow metal door embodying the improved construction and which has been produced by the novel method of this invention;

Fig. 2 is a perspective view showing one of the pan-like units or sub-assemblies used in forming the improved metal door;

Fig. 3 is a transverse section taken through the door, as indicated by line 33 of Fig. 1;

Figs. 4 and 5 are partial vertical sections taken through the top and bottom edges of the door, as indicatedby lines 4-4 and 5-5, respectively, of Fig. 1;

Fig. 6 is a partial side elevation showing the reinforced construction by which the door is adapted for the mounting of a hinge butt thereon;

Fig. 7 is a partial side elevation similar to Fig. 6, but with the hinge butt omitted;

Fig. 8 is a partial vertical section taken through the door adjacent one of the hinge mounts, as indicated by line 88 of Figs. 1 and 6;

Fig. 9 is a partial edge view of the door showing one of the hinge mounts as formed by the hinge reinforcing elements, but with the hinge butt removed;

Fig. is a face view showing the complemental hinge reinforcing elements in detached relation;

Fig. 11 is a partial vertical section taken adjacent the lock reinforcement, as indicated by section lines i|-H of Figs. 1 and 12 and showing the door lock installed in the metal door;

Fig. 12 is a partial vertical section taken on the irregular section line l2-l2 of Fig. 11 and presenting a face view of one of the lock reinforcing elements;

Fig. 13 is a partial transverse section taken through the door above the lock reinforcement as indicated by line l3-|3 of Fig. 11, the door lock being shown only in construction lines;

Fig. 14 is a perspective view of a portion of one of the lock-stile panels with its lock reinforcing element assembled therein;

Fig. 15 is a partial edge View of the door showing the lock reinforcement and the lock-receiving recess, but with the lock removed;

Fig. 16 is a perspective view similar to Fig. 14, i

but showing a modified form of lock reinforcing element;

Fig. 17 is a partial edge view of the door showing the lock reinforcement and lock-receiving recess provided therein by the modified lock reinforcing elements, but with the lock removed;

Fig. 18 is a partial transverse section taken through the door above the modified lock rein? forcement, as indicated by line l8-I8 of Fig. 1'7;

Fig. 19 is a transverse section similar to Fig. '3 but taken through another modified form of the improved hollow metal door; and

Fig. 20 is a partial end view of a conventional welding tool adapted for insertion into the hollow door structure in carrying out the novel method.

The improved hollow metal door I!) comprises a pair of generally flat shallow pan-like units or sub-assemblies II and I2 which have substantially smooth flat outer faces forming the side faces 13 and 14 of the door and which units are connected together in face-to-face complemental relation as shown in Fig. 3 to form the hollow door structure. The units or sub-assemblies H and 12 are similar in construction and each comprises a group-of preformed sheet metal panels disposed in coextending relation and having their adjacent edges connected together. In this instance each unit comprises three such preformed sheet metal panels consisting of the edge or stile panels 15 and 46 and an intermediate or body panel [1. In the completed door the edge panel I5 forms a portion of the stile of the door on which the hinge butts l8 are mounted and for that reason can be conveniently referred to as ahinge-stile panel. Similarly, the edge panel 15 forms a portion of the stile on which the door lock mechanism I 9 is mounted and can therefore be referred to as a lock-stile panel.

Since the pan-like units II and i2 are similar in construction and are composed of similar groups of corresponding identical preformed sheet metal panels, it will only be necessary to describe in detail one of these units, such as the unit H. The hinge-stile panel [5 is of a substantially C-shaped cross-section having reversely bent edge portions which form thereon the longitudinal edge flanges 2t and 2 l and the in-turned longitudinal edge flange extensions 22 and 23 which are hereinafter referred to as connecting flanges. The edge flanges 2 3 and 2| extend rearwardly at substantially right angles to the flat sheet or web 24 forming the outer face of this panel. The lock-stile panel [6 is also of C- shaped cross-section and has reversely bent edge portions forming thereon the longitudinal edge flanges 25 and 26 which extend rearwardly at substantially right angles to the flat plate or web portion 21 and the in-turned longitudinal flange extensions 28 and 29 which are hereinafter designated connecting flanges.

The intermediate panel I! is a channel-shaped panel having a substantially flat plate or web portion 30 and longitudinal edge flanges 3| and 32 extending at substantially right angles thereto. In forming the unit H the panels l5, l6 and II are disposed in sideby-side coextending relation with the flat web portions 24, 21' and 30 thereof lying in substantially the same plane.

The edge panel 15 is connected to the intermediate panel I'! by welding the'flanges 20 and 32 together. Similarly, the edge panel 16 is connected to the intermediate panel I! by welding the edge flanges 25 and 3| together. The welding of these pairs of flanges can be easily and rapidly carried out by conventional welding apparatus adapted to form rows of spot welds 33 and 34, because at this time these pairs of flanges are exposed and readily accessible.

The units H and I2 have longitudinal and transverse plan dimensions which correspond respectively with the dimensions of the door 10 in height and width. These units also have a depth or thickness substantially equal to one-half of the thickness of the door. The units H and I2 are assembled with their open or recessed sides in face-to-face complemental relation to form the hollow door structure, as mentioned above, which brings the connecting flanges 22, 23, 28 and .29 of the two units into paired relation and in face-to-face engagement with each other, as shown in Fig. 3. When the units H and 12 have been thus assembled, the cooperating hinge-stile panels I5 of the two units define a longitudinal passage 35 in the door structure and, similarly, the cooperating lock-stile panels l6 and the 00- operating intermediate panels 5'! form longitudinal passages 36 and 31.

The units II and I2 are connected together in this complemental relation by rows of spot welds 38, 39, 40 and 4| formed on the paired connecting flanges 22, 23, 28 and 29. The welding of these connecting flanges together can be carried out by the use of conventional welding apparatus which is inserted, in succession, into the passages 35 and 36 by movement endwise of the door structure. For this purpose a welding apparatus can be used having a relatively long thin flat beam portion which is provided at the end thereof with a pair of arms 42 and 43, as shown in Fig. 20, carrying cooperating welding contacts or electrodes 44 and 45. In welding apparatus of this type one of the arms, such as the arm 42, is pivoted for swinging movement relative to the other arm to cause opening and closing of the electrodes. This swinging movement can be produced by a rock shaft 48 which extends longitudinally of the beam portion of the apparatus.

The hollow door structure formed by the complemental units H and I2, as described above, can be reinforced and the ends of the passages 35, 36 and 31 thereof can be closed by the use of channel members 41 and 48 at the top and bottom edges of the door. These channel mem bers can be recessed into the top andbottom edges of the door, as shown in Figs. 4 and 5, and can have their flanges connected to the sides I3 and I4 of the door by rows of spot welds 49.

Before the hinge-stile panels I5 are incorpor ated into the units II and I2, they are notched to provide partial hinge butt recesses and are also provided with hinge reinforcing elements 50 and 5| which form partial hinge butt mounts and together constitute the hinge mount 52 (see Fig. 9). Likewise, before the lock-stile panels I6 are incorporated into the units II and I2 they are notched to provide partial lock-receiving recesses and are also provided with lockreinforcing elements 53 and 54 forming partial door-lock mounts which together constitute a door-lock mount 55 '(see Figs. 11, 13 and The mounting of the hingeand lock-reinforcing elements on the panels I5 and I6 prior to these panels being incorporated into the units II and I2 is very important because, at this time, the panels are still open such that the reinforcing elements can be quickly and easily assembled therein and can be welded in place by welding operations which require only the use of conventional welding equipment. These hingeand lock-reinforcing elements 50, 5| and 53, 54 and the mounting thereof on the panels I5 and I6 will now be described in greater detail.

As shown in Fig. 9 of the drawings, the hingestile panels of the respective units I I and I2 have notched recesses or openings 56 and 51 formed therein. The opening 51 of the unit I2 extends through the edge flange 2|, but does not extend across the full width of this flange. ing 56 of the unit II extends entirely across the flange 2| and for a short distance into the flat plate or web portion 24 of the hinge-stile panel I5. The portions of the connecting flanges 23 lying between the top and bottom edges 58 and 59 of these openings are entirely cut away as is clearly indicated in Figs. 6, 7 and 8. The two openings or partial recesses 56 and 51 of the units II and I2 are complemental to each other and together form a hinge butt recess IBa in which the butt I8 is mounted, as shown in Figs. 6 and 8.

The hinge-reinforcing elements 50 and 5| are elongated strip-like plates which are mounted in the respective units II and I2 against the inner faces of the edge flanges 2| thereof and in longitudinal spanning relation to the partial recesses 56 and 51. The reinforcing element 50 has substantially flat connecting portions 500! and 501) at the ends thereof which are in face-toface engagement with the inside of the edge flange 2| of the unit I I and are connected thereto by the spot welds 60. The intermediate portion 500 of the reinforcing element 50 is offset from the plane of the end portions and cooperates with the edge flange 2| of the unit II to give the hinge recess Ifla a depth approximately equal to the thickness of the plate portion of the hinge butt IB. Similarly, the reinforcing element 5| is provided with end portions 5Ia and 5|b which are spot welded to the flange 2| of the unit I2 and. with an offset intermediate portion 5| 0.

As shown in Fig. 10 the intermediate portion of the reinforcing element 5| is somewhat wider than the intermediate portion of the reinforcing element 50. When the reinforcing elements are assembled in the door structure as shown in Fig. 9 and the units I0 and II are brought into their complemental relation, these intermediate portions have matching engagement along their 3-,

The openadjacent edges as represented by the irregular line or joint 6|. The joint 6| is so formed that it includes the offset matching portions 6 I a and 6 lb and when the reinforcing elements are in the proper position longitudinally of the door, these matching portions will register with each other. The hinge-reinforcing elements 5|! and 5| are provided with groups of tap openings 62 and 63, there being three such openings in each group and the openings of each reinforcing element being spaced apart equal distances longitudinally of the element and also being spaced inwardly the same distance from the joint 6|.

- As shown in Figs. 9 and 10 of the drawings, the ends a and 50b of the hinge-reinforcing element 50 and the ends 5| a and 5|b of the reinforcing element 5| are somewhat narrower than the intermediate portions of these elements and are of a width to fit snugly into the panels I5 against the inner faces of the edge flanges 2| thereof. Because the paired end portions 50a, 5|a and 50b, 5|b of the hinge-reinforcing elements so and 5| are of this reduced width they define therebetween the longitudinal slots 64, as shown in Fig. 10, which accommodate the paired connecting flanges 23 of the panels I 5 when the units I and I2 are in assembled position, as shown in Fig. 9. The portions 64a of the hinge-reinforcing elements 5!) and 5| which define the inner ends of the slots 64 cooperate with the edges of the cutaway portions of the connecting flanges 23 for locating the reinforcing elements longitudinally of the panels I5, as is also shown in Fig. 9. From the shape and arrangement just described above for the notched recesses 56 and 51 of the'hingestile panels I5 of the units II and I2 and for the hinge-reinforcing elements 50 and 5|, it will be seen that these reinforcing elements will be selflocating in the panels I5 with respect to the partial recesses56 and 51 thereof and, when the units I and I2 are assembled in their face-to-face complemental relation, the reinforcing elements will form the hinge mount 52 lying inwardly of the recess I 8a and whose end slots 64 straddle the adj acent portions of the paired connecting flanges By providing the hinge reinforcing elements 50' and 5| with three of the tap openings 62, 63, the hinge mount 52 will be adapted for the mounting of the hinge butt I8 thereon regardless of whether this butt is a so-called template butt or a nontemplate butt. The hinge butt I 8 is here shown as being connected with the mount 52 by means of two screws 62a engaging in the two end tap openings 62 of the reinforcing element 59 and a single screw 63a engaging in the center tap opening 63 of the reinforcing element 5|. When the hinge butt I8 is connected to the mount 52 as" just described, it will be observed that the butt acts as a strap or plate which spans the joint 6| between the two reinforcing elements 5!! and 5|. It will thus be recognized that the elements 5|! and 5I reinforce the hinge-stile panels I5 of the units II and I2 at the point where these panels are notched to form the hinge recess and they also form complemental joint elements which are connected by the hinge butt I8 to strongly tie the units and I2 together at this point.

The hinge mount 52 is here shown as having longitudinal slots 65 therein which are exposed on the edge of the hinge-stile of the door ,I 6 prior to the mounting of the hinge butt I8 thereon.

These slots afford openings into which a conveyor;

hook or other work handling means can engage. for lifting or handling the door. The slots 65 7 are desirable for thispurpose although'they can be omitted when not required.

From the shape of the hinge-reinforcing ele- ;ments Hand 51 and theshape and location of the-partial openings-56 and 5'! of the panels l5 of the units II and I2, as above described, it will be seen that these hinge-reinforcing elements will be substantially self-locating in the panels during the operation of assembling them therein. This saves much time and expense because no cuttin or fitting operations are needed. Moreover,-as mentioned above, the panels l5 are still open at this time'which facilitates theassembly of the hinge-reinforcing elements 5'. and 5| therein and permits the welding of these elements in place to be carried out rapidly and by the use of conventional welding equipment.

As shown in the drawings, the lock-stile panels [6 of the units H and [2 have their edge flanges .25notched to provide partial recesses 65 and 65 therein which together form a lock-receiving rccess 61 in the corresponding edge of the door I adapted to accommodate the door-lock 58, as

' place therein prior to the incorporation of these .panels in the respective units H and I2. .the reinforcing elements are put into the panels When I5 at this time, the panels are open such that the reinforcing elements can be quickly and easily assembled therein and can be readily welded in place by the use of conventional welding apparatus. It is also important that the shape of the reinforcing elements is such that these elements will be self-locating in the panels 66 and this will permit these elements to be assembled in place in the panels with a minimum labor expenditure and without need for any cutting or fitting operations.

formed by the reinforcing elements 53 and 54 will now be described in greater detail.

.As best seen in Figs. 14 and of the drawings,

the partial recesses 65 and 56 of the lock-stile panels l6 of the units H and I2 extend part way across the edge flanges and extend entirely through the connecting flanges 28 as an interruption or gap in the latter. These partial recesses and G6 are complemental to each other and together form the lock-receiving recess 61 in the edge of the door and with which recess the gap of the flanges 28 is substantially longitudinally coextension. This recess is of a length and width to snugly receive the face plate 10 of the lock mechanism 68 as shown in Figs. 11 and 12.

The lock reinforcing elements 53 and 54 are made of sheet metal and are identical in construction such that they can be produced from the same dies. Each of these reinforcing elements is provided with a substantially flat body portion H and with a pair of angularly disposed arms 12 and 13 adjacent its ends. Each element is also provided with a pair of angularly disposed connecting and positioning lugs 14 and 15, preferably right-angle lugs, located adjacent the arms I2 and 13. When the reinforcing elements 53 and 54 are assembled in the panels IS, the fiat plate portions H are disposed in engagement with and welded to the inner sur- The lock-receiving recess 61 of the door structure and the lock mount 55 '8 face of the flat web portions 2! of these panels. The welds formed for this purpose are here represented by the spot welds X.

When the lock-reinforcing elements 53 and 54 are located adjacent the partial recesses 65 and 33 of the panels IS, the angular'arms 12 and 13 seat against the inner faces of the edge flanges 25 of the panels and inthe door structure formed by the units H and I2 these arms of the reinforcing elements are in paired relation straddling the connecting flanges 28, asshown in Figs. 11 and 13. The spacing of the connecting lugs .74 and 15 is such that the remote edges of these o accurately positioned in the panels I6 and will be substantially self-locating therein by the mere insertion of these reinforcing elements in the respective panels.

When the units II and I2 are assembled in their complemental relation to form the hollow door structure, as explained above, the connecting lugs 74 and 15 of the reinforcing elements 53 and 54 extend into overlapping relation with each other, as shown in Figs. 11 and 13. Each of the lugs 15 has a tap opening 18 therein and each of the lugs 14 has a somewhat larger clearance opening 1'! therein. The position of these lugsin the assembled door structure is such that the lugs 14 overlie the lugs 15 and the clearance openings 11 expose the tap openings 16. The tops of the lugs 14 and 15 are offset slightly inwardly from the tops of the arms 12 and 13 and when the connecting lugs are in their overlapping relation, as shown in Fig. 13, they will form the above-mentioned mount 55 for the door lock 68.

By reason of the inwardly offset relation of the connecting lugs 14 and 15 the mount '55 formed thereby will be located relative to the edge of the door such that when the lock 68 is assembled in position, the face plate '10 thereof will be substantially flush with the edge face of the door. The lock 68 is secured in place by screws"!!! which extend through the face plate 10 and through the clearance openings 11 and engage in the tap openings 16. When the lock is assembled in this position, the screws I8 also form an interlock for the paired connecting lugs 14 and 15.0f the reinforcing elements 53 and 54, thus providing a strong connection between the units II andl2 at this point.

As shown in the drawings the lock-reinforcing elements 53 and 54 are provided with a pair of openings 19 and 80, one of which accommodates the rotary spindle 81 of the door-lock 68 on which the door knob 82 is mounted. The other of these two openings is located opposite the keyhole of the escutcheon plate 84. When the reinforcing elements 53 and 54 are welded in place in the panels IS the spot welds X are so located that some or all of them will be hidden by the escutcheon plate 84 on the knob side of the door and by the escutcheon member 85 on the opposite side of the door. At a point intermediate the openings 19 and the reinforcing elements 53 and 54 are provided with inwardly offset partially sheared strips or fingers 86 which serve as a locating means for the lock 68 and prevent shifting or rattling thereof. The reinforcing members 53 and 54 are also provided with suitably located tap openings 81 to accommodate screws 88 by which the escutcheon members 84 and 85 are mounted on the door.

Figs. l6, l7 and 18 show a modified construction for a pair of complemental lockereinfo-rcing elements 90 and 9|. The lock-reinforced elements 90 and 9| are similar .to the lock-reinforcing elements 53 and 54 above described and are used in the same manner and for the same purpose. The reinforcing elements 90 and 9| differ from the reinforcing elements 53 and 54 in that the interlock between the pair of co-mplemental reinforcing elements is obtained in the modified construction by the use of tongue and slot elements in addition to the screws which connect the door lock to the lock mount.

The modified lock-reinforcing elements 90 and 9| carry angularly disposed connecting lugs 92 and 93 which correspond in location and function with the above described connecting lugs units and I2 are assembled in their complemental relation to form the hollow door structure, the lugs 92 extend in overlying relation to the lugs 93 with the fingers 94 engaging in the slots 95. The engagement of the fingers in these slots provides an interlock between the reinforcing elements 90 and 9| and enables these elements to more strongly reinforce the door structure at the lock recess. The lugs 93 have tap openings 93a therein and when the door lock is mounted on the door by screws engaging in these openings, the screws also form an interlock between the paired reinforcing elements 90 and 9|.

As shown in Fig. 16, the connecting lugs 92 and 93 of the reinforcing elements 90 and 9| are provided with extension lugs 96 and 91 which extend toward the arms 12 and 13 and engage behind the connecting flanges 28. The extension lugs 96 and 91 are of a size to fit snugly between the flanges 28 and the flat plate portions 21 of the panels l6. These extension lugs thus cooperate with the connecting flanges 28 for assisting in locating the reinforcing elements in proper position in the panels Hi and also for the purpose of holding the edge flanges of the panels against deflection.

Fig. 19 shows another hollow metal door I which is a modification of the door |0 described above. From a comparison of Fig. 19 with Fig. 3 it will be observed that the modified door I00 is also formed by a pair of preformed complemental units or sub-assemblies II and I2 and that each of these units comprises a pair of stile panels i and Hi and an intermediate or body panel ll. In the modified door I00, however, these panels are of a somewhat different crosssectional shape by reason of the fact that the paired connecting flanges IM and I02 are carried by the intermediate panels I! instead of by the stile panel-s.

In this modified door I90 each of the intermediate panels is generally channel-shaped in cross-section but has the longitudinal connecting flanges |0| and I02 formed at the sides thereof as out-turned extensions of their longitudinal edge flanges 3| and 32. When the units H and 2 are disposed in face-to-face relation the connecting flanges llll of the two intermediate panels I! are in surface engagement with each other and form a longitudinal rib which projects into the longitudinal passage 36 formed ime stile panels |6. Similarly, the connectlng flanges I02 of the panels ll are in surface engagement, with each other'and form a longitudinal rib whi ch projects into the longitudinal passage 35 formed by the stile panels l5. The paired flanges |0| are connected together by longitudinally spaced welds Hi3 and the paired flanges |02are connected together by similar welds I04.

The modified construction of Fig. 19 will provide, 'afdoor' I00 which is very strongand rugged and which will be wellsuited for use as a fire door. The'ribs formed by the paired connecting flanges ,lfil and I02'will greatly strengthen the intermediate portion of the door which is formed by the panels I1 and will enable this portion to better resist the stresses which develop when the door issubjected to heat. I

From the foregoing description and the accompanying drawings it will now be readily understood that the present invention provides a novel construction and method of manufacture for hollow sheet metal doors in which groups of panels are first welded together to form pan-like units and the'units thus formed are then connectedin complemental relation to form the hollow door structure. It will also be understood that this invention provides a novel construction and method in which hingeand lockreinforcing elements are provided in the door with a minimum expenditure of labor in assembling and welding the elements in place and with substantially no cutting or fitting operations being needed during the assembly work. In connection with these reinforcing elements it will be further understood that they are of a novel construction which renders them self-locating in the panels during assembly and which results in an interlock between these elements for strongly reinforcing the door structure at the location of its hingeand lock-receiving recesses. Additionally, it will be recognized that in the novel method and consruction herein disclosed most of the welding is carried out while the parts are in an open and exposed condition which permits the welding to be carried out easily and rapidly with conventional welding apparatus and only a small part of the welding is required to be performed internally of the hollow door strucure.

Having thus described my invention, I claim:

1. In a sheet metal door, a hollow stile having opposed side walls and an edge wall defining a longitudinal edge face of the door, an internal longitudinal flange carried by said edge Wall and projecting from the inner surface thereof, said edge wall having an opening therein interruptmg said flange and adapted to receive the plate portion of a door-lock having plate and body portions, and a reinforcement located in and reinforcing said stile at the location of said opening, said reinforcement comprising a pair of complemental one-piece plate members having angular lug portions extending across said opening in a spaced apart relation longitudinally of the opening to accommodate the body portion of said door-lock therebetween, said angular lug portions comprising a front lug and a rear lug on each plate member lying inwardly of the plane of said edge face with the front lugs extending in overlapping relation to the rear lugs such that said angular lug portions form a mount adapted for the attachment of theplate portion of said door-lock thereto, said angular lug portions also 11 forming locating elements and being in engage ment with said flange at said interruption thereof for locating said plate members relative to said opening and longitudinally of said stile and said plate members being welded to said side walls.

2. In a sheet metal door, a hollow stile having opposed side walls and an edge wall defining a longitudinal edge face of the door, said edge wall having an opening therein adapted to receive the plate-portion of a door-lock havin plate and body portions, and a pair of complemental'reinforcing plates welded in place in said stile and against said side walls substantially at the location of said opening and adapted to accommodate the body portion of said door-lock therebetween, said reinforcing plates each having a front lug and a rear lug extending across said openingadjacent the ends thereof but lying inwardly of the plane of said edge face and forming a mount adapted for the attachment of the plate portion of said door-lock thereto, said front and rear lugs being in pairedoverlapping relation and the rear lugs of the pairs having tap holes therein and the front lugs having clear-' ance holes therein exposing said tap holes.

3. In a sheet metal door, a hollow stile having wall means including opposed side walls and an edge wall'defining a longitudinal edge face of the door, internal flange means carried by said edge wall and projecting inwardly therefrom, said edge wall having an opening therein extending throughsaid edge face and interrupting said internal flange means and forming a recess adapted to receive the plate portion of a door-lock having plate and body portions, and'a pair of complemental reinforcing plates weldedin place in said hollow stile and against said side walls substantially at the location of said recess and adapted to accommodate the body portion of said doorlock therebetween, said reinforcing plates each having a front lug and a rear'lug extending across said recess adjacent the ends thereof but lying inwardly of the plane of said edge face and forming a mount adapted for the attachment of the plate portion of said door-look thereto, said front and rear lugs being in paired overlapping relation and said rear lugs having tap holes therein and said front lugs having clearance holes therein exposing said tap holes, said reinforcing plates being located in said stile longitudinally thereof and relative to said recess by engagement of the lugs of said plates with said internal flange means at the interruption thereof and said reinforcing plates also having flange portionsseated against the inner face of said edge wall and locating said paired l-ugs in the inwardly lying relation to the plane of said edge face.

4. In a sheet metal door, a hollow stile having wall means including opposed side walls and an edge wall defining a longitudinal edge face of the door, said edge wall having an opening therein extending through said edge face and forming a recess adapted to receive the plate portion of a door-lock having plate and body portions, and a pair of complemental reinforcing plates located in said stile and having paired lugs extending across said recess adjacent the ends thereof and inwardly of the plane of 7 said edge face and forming a mount adapted for the attachment of the plate portion of said door lock thereto, said reinforcing plates being welded in place in said stile by attachment to the side walls thereof and said paired lugs having cooperating tongue and aee giei 12 slot elements interlocking said reinforcing plates with each other. i

5. In a sheet metal door,'a hollow stile having wall means including opposed side walls and an edge wall defining a longitudinal edge face of the door, said edge wall having an opening therein extending through said edge face and forming a recess adapted to receive the plate portion of a door-lock having plate and body portions, and a pair of complemental reinforcing plates welded in place in said stile adjacent the location of said recess by attachment to said side walls and adapted to accommodate the body portion of said door-lock therebetween, said reinforcing plates each having a front lug and a rear lug extending across said recess adjacent the ends thereof but inwardly of the plane of said edge face and forming a mount adapted for the attachment of the plate portion of said door-lock thereto, said front and rear lugs being in paired overlapping relation and said rear lugs having tap holes therein and the front lugs having clearance holes therein exposing said tap holes, said paired lugs also having cooperating tongue and slot elements thereon interlocking said reinforcing plates with each other.

6. In a sheet metal door, a hollow stile having wall means including opposed side walls and an edge wall defining a longitudinal edge face of the door internal flange means carried by said edge wall and projecting inwardly therefrom, said edge wall having an opening therein extending through said edge face and interrupting said internal flange means and forming a recess adapted to receive the plate portions of a door-lock having plate and body portions, and a pair of complemental reinforcing plates welded in place in said hollow stile at the location of said recess and against said side walls and adapted to accommodate the body portion of said door-lock therebetween, said reinforcing plates each having a front lug and a rear lug extending across said recess adjacent the ends thereof but lying inwardly of the plane of said edge face and forming a mount adapted for the attachment of the plate portion of said door-look thereto, said front and rear lugs being in paired overlapping relation and said rear lugs having tap holes therein and said front lugs having clearance holes therein expos ing said tap holes, said reinforcing plates being located in said stile longitudinally thereof and relative to said recess by engagement of the lugs of said plates with said internal flange means at the" interruption thereof and said reinforcing platesalso having flange portions seated against the inner face of said edge wall and locating said paired lugs in the inwardly lying relation tothe plane of said edge face, said paired overlapping lugs having cooperating tongue and slot elements interlocking said reinforcing plates with each other.

7. In a sheet metal door, wall means defining a hollow stile having a longitudinal edge face thereon and also having internal flange means carried by said wall means and projecting inwardly therefrom, a hardware member, said wall means having an opening therein extending through said edge face and interrupting said internal flange means and forming a recess adapted to receive said hardware member, a reinforcemnt in said stile adjacent the location of said recess and having portions spaced inwardly from the plane of said edge face and forming a mount for said hardware member, said reinforcement comprising a' pair of complemental one-piece plate members welded in place 011 said wall means and having portions thereof engaging said flange means at the interruption thereof for locating said plate members in said stile and relative to said recess, said hardware member being disposed in said recess and having one face thereof lying in substantially flush relation to the surface of said edge face and the opposite face lying against said mount, and means securing said hardware member to said mount.

8. In a sheet metal door, a hollow stile having a longitudinal passage therein and also having walls including a pair of opposed side walls and an edge wall defining a longitudinal edge face of the door, an internal longitudinal flange carried by said edge wall and projecting from the inner surface thereof into said passage, said edge wall having an opening therein communicating with said passage and said flange having a gap therein substantially longitudinally coextensive with the edge wall opening, said opening and gap being adapted to receive a door lock, and a combined hardware mount and stile reinforcement means comprising a pair of complemental onepiece metal plate reinforcement members disposed in said passage and having substantially right-angle lug locating portions thereon adjacent opposite ends of said reinforcement means and engaging said flange at the ends of said gap for positioning said reinforcement members longitudinally in said passage and relative to said opening, said reinforcement members being secured to said side walls by welded connections and having said right-angle lug locating portions thereof exposed through said opening and forming a mount for said door lock.

9. In a sheet metal door, a hollow stile having a longitudinal passage therein and also having .walls including opposed side walls and an edge wall defining a longitudinal edge face of the door, an internal longitudinal flange carried by said edge wall and projecting from the inner surface thereof into said passage and being spaced from said side walls by longitudinal channel pertions of said passage, said edge wall having an opening therein communicating with said passage and interrupting said flange and adapted to receive a hinge butt, and a pair of metal plate members having relatively close fitting engagement in said channel portions and also having locating portions engaging said flange at said interruption thereof for locating said plate members longitudinally of said channel portions and relative to said opening, said plate members being welded to said edge wall in spanning relation to said opening and having portions exposed 14 through said opening and forming a mount for said hinge butt.

10. Sheet metal door structure as defined in claim 9 in which said plate members have edge portions in an interfitting meeting engagement within the interruption of said flange.

11. In a sheet metal door, a hollow stile having a longitudinal passage therein and also having Walls including an edge wall defining a longitudinal edge face of the door, an internal longitudinal flange carried by said edge wall and projecting from the inner surface thereof into said passage, said edge Wall having an opening therein communicating with said passage and interrupting said flange and adapted to receive a hinge butt, and a pair of complemental one piece metal plate stile reinforcement members disposed in said passage and having locating portions engaging said flange at said interruption thereof for positioning said reinforcement members relative to said opening, said reinforcement members being secured to said edge wall in spanning relation to said opening and having portions thereof exposed through said opening and forming a mount for said hinge butt, said reinforcement members have preformed tap holes therein and which tap holes are located so as to provide two different groups of such tap holes adapting said mount to receive either of two hinge butts having differently grouped fastening holes.

12. Sheet metal door structure as defined in claim 8 in which said internal flange divides said longitudinal passage of the stile into coextending channel portions and in which said reinforcement members have angular lug portions forming locating elements extending into said channel portions and seating against the inner surface of said edge wall adjacent opposite ends of said opening.

EARL BOUGHTON.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date Re. 21,024 Schlage Mar. 7, 1939 963,450 Lowe July 5, 1910 1,039,292 Johnson Sept. 24, 1912 1,323,753 Gogay Dec. 2, 1919 1,748,195 Stevens Feb. 25, 1930 1,822,251 Thies Sept. 8, 1931 2,013,412 Koenig et a1 Sept. 3, 1935 FOREIGN PATENTS Number Country Date 376,814 Great Britain July 14, 1932 471,258 Great Britain Sept. 1, 1937 

